Bosch RA1171 User manual

Operating/Safety Instructions

Consignes de fonctionnement/sécurité

Instrucciones de funcionamiento y seguridad

RA1171

IMPORTANT:

Read Before Using

IMPORTANT :

Lire avant usage

IMPORTANTE:

Leer antes de usar

For English

See page 2

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Voir page 32

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Consumer Information

Renseignement des consommateurs

Información para el consumidor

Toll Free Number: Appel gratuit : Número de teléfono gratuito:

1-877-BOSCH99 (1-877-267-2499) http://www.boschtools.com

2 610 930 993 09/05

2

Table of Contents

IMPORTANT SAFETY INFORMATION . . .2–5

Parts List . . . . . . . . . . . . . . . . . . . . . . . . .6–9

Router Table Assembly . . . . . . . . . . . .10–18

Router Table Operation . . . . . . . . . . . .19–31

Power Tool Safety Rules

Work Area

Keep your work area clean and well lit. Cluttered benches

and dark areas invite accidents.

Do not operate power tools in explosive atmospheres,

such as in the presence of flammable liquids, gases, or

dust. Power tools create sparks which may ignite the dust

or fumes.

Keep bystanders, children, and visitors away while

operating a power tool. Distractions can cause you to

lose control.

Electrical Safety

Grounded tools must be plugged into an outlet properly

installed and grounded in accordance with all codes

and ordinances. Never remove the grounding prong or

modify the plug in any way. Do not use any adaptor

plugs. Check with a qualified electrician if you are in

doubt as to whether the outlet is properly grounded.

If the tools should electrically malfunction or break down,

grounding provides a low resistance path to carry electricity

away from the user. Improper grounding can shock, burn,

or electrocute. Grounded tools are equipped with three-

conductor cord and three-prong type plugs. Before plugging

in the tool, be certain the outlet voltage supplied is within the

voltage marked on the nameplate. Do not use "AC only"

rated tools with a DC power supply.

Double-insulated tools are equipped with a polarized

plug (one blade is wider than the other.) This plug will fit

in a polarized outlet only one way. If the plug does not

fit fully in the outlet, reverse the plug. If it still does not

fit, contact a qualified electrician to install a polarized

outlet. Do not change the plug in any way. Double

Insulation eliminates the need for the three-wire

grounded power cord and grounded power supply system.

Before plugging in the tool, be certain the outlet voltage

supplied is within the voltage marked on the nameplate.

Do not use “AC only” rated tools with a DC power supply.

Avoid body contact with grounded surfaces such as

pipes, radiators, ranges and refrigerators. There is an

increased risk of electric shock if your body is grounded. If

operating the power tool in damp locations is unavoidable, a

Ground Fault Circuit Interrupter must be used to supply the

power to your tool. Electrician’s rubber gloves and footwear

will further enhance your personal safety.

Don’t expose power tools to rain or wet conditions.

Water entering a power tool will increase the risk of

electric shock.

Do not abuse the cord. Never use the cord to carry the

tools or pull the plug from an outlet. Keep cord away

from heat, oil, sharp edges, or moving parts. Replace

damaged cords immediately. Damaged cords increase

the risk of electric shock.

When operating a power tool outside, use an outdoor

extension cord marked “W-A” or “W.” These cords are

rated for outdoor use and reduce the risk of electric shock.

Refer to “Important Information About Extension Cords” in

your router table manual.

Personal Safety

Stay alert, watch what you are doing and use common

sense when operating a power tool. Do not use tool

while tired or under the influence of drugs, alcohol, or

medication. A moment of inattention while operating power

tools may result in serious personal injury.

Keep guards in place. Maintain the guards in working order

and in proper adjustment and alignment.

Avoid accidental starting. Be sure switch is “OFF”

before plugging in. Carrying tools with your finger on

the switch or plugging in tools that have the switch “ON”

invites accidents.

Remove adjusting keys or wrenches before turning

the tool “ON.” A wrench or a key that is left attached to

a rotating part of the tool may result in personal injury.

Do not overreach. Keep proper footing and balance

at all times. Proper footing and balance enable better

control of the tool in unexpected situations.

Use safety goggles (head protection). Wear safety

goggles (must comply with ANSI Standard Z87.1) at all

times. Wear non-slip footwear and a hard hat, if appropriate.

Also, use face or dust mask if cutting operation is dusty

and ear protectors (plugs or muffs) during extended periods

of operation.

Tool Use and Care

Use clamps or other practical way to secure and

support the workpiece to a stable platform. Holding the

work by hand or against your body is unstable and may lead

to loss of control.

Read and understand the tool manual and these instructions for the

use of this table with your router. Failure to follow all instructions listed below may

result in serious personal injury.

SAVE THESE INSTRUCTIONS

3

Do not force tool. Use the correct tool for your

application. The correct tool will do the job better and

safer at the rate for which it is designed.

Do not use tool if switch does not turn it “ON” or

“OFF.” Any tool that cannot be controlled with the switch

is dangerous and must be repaired.

Disconnect the plug from the power source before

making any adjustments, changing accessories, or

storing the tool. Such preventive safety measures reduce

the risk of starting the tool accidentally.

Keep guards in place. Maintain the guards in working order

and in proper adjustment and alignment.

Store idle tools out of reach of children and other

untrained persons. Tools are dangerous in the hands of

untrained users.

Never leave tools running unattended. Turn the power

OFF. DO NOT leave tool until it comes to a complete stop.

Maintain tools with care. Keep cutting tools sharp and

clean. Properly maintained tools, with sharp cutting edges

are less likely to bind and are easier to control. Any

alteration or modification is a misuse and may result in

a dangerous condition.

Check for damaged guards or parts, misalignment or

binding of moving parts, breakage of parts, and any

other condition that may affect the tool’s operation.

If damaged, have the tool properly repaired or replaced

before using. Many accidents are caused by poorly

maintained tools. Develop a periodic maintenance

schedule for your tool.

Use only accessories that are recommended by the

manufacturer for your model. Accessories that may be

suitable for one tool may become hazardous when used

on another tool.

Service

Tool service must be performed only by qualified

repair personnel. Service or maintenance performed by

unqualified personnel could result in a risk of injury. For

example: internal wires may be misplaced or pinched;

safety guard return springs may be improperly mounted.

When servicing a tool, use only identical replacement

parts. Use of unauthorized parts or failure to follow

maintenance instructions may create a risk of electric shock

or injury. Certain cleaning agents such as gasoline, carbon

tetrachloride, and ammonia may damage plastic parts.

Additional Safety Warnings for Router Tables

Read and understand table and router manual and

accessory warnings. Failure to follow all instructions

and warnings may result in serious personal injury.

Fully assemble and tighten all fasteners required for

this table and for mounting the router to the plate.

Do not use the router table until all assembly and

installation steps have been completed. Check the

table and the router to make sure fasteners are still

tight before each use. A loose table is unstable and

may shift in use.

Make certain the router is not plugged into a power out-

let when installing into the table, removing from table,

making adjustments or changing accessories. Router

could accidentally start.

Do not plug router motor power cord into standard wall

outlet. It must be plugged into the router table switch.

Power tool switches and controls need to be within your

reach in emergency situations.

Before operating, make sure the entire unit (table with

router installed) is placed on and secured to a solid, flat,

level surface and will not tip. Use of auxiliary in-feed

and out-feed supports is necessary for long or wide

workpieces. Long workpieces without adequate support

can flip off the table or cause the table to tip over.

Be certain router motor is fully and securely clamped in

the router base. Periodically check the base fastener

clamping tightness. Router motor can vibrate loose from

the base during use and fall from table.

Do not use the router table without the overhead guard

or auxiliary bit guard. Remove all dust, chips, and any

other foreign particles that can affect its function.

Adjust the guard height so that it clears the router bit

and the workpiece. The guard will aid in keeping hands

from unintended contact with rotating bit.

Never place your fingers near a spinning bit or under

the guard when router is plugged in. Never hold the

workpiece on the out-feed side of bit. Pressing the

workpiece against the out-feed side of the fence may

cause material binding and possible kickback pulling

hand back into bit.

Guide workpiece by the fence to maintain control of

workpiece. Do not place material between router bit and

fence while routing the edge. This placement will cause

the material to become wedged, making kickback possible.

Routers are intended for working with wood, woodlike

products and plastic or laminates, not for cutting or

shaping metals. Be sure workpiece does not contain

nails, etc. Cutting nails may cause loss of control.

Do not use bits that have a cutting diameter that

exceeds the clearance hole in the tabletop insert.

Bit could contact insert ring, throwing fragments.

Install bit in accordance with instructions in router

manual and securely clamp the router bit in the collet

chuck before making any cuts to avoid bit becoming loose

during operation.

Never use dull or damaged bits. Sharp bits must be

handled with care. Damaged bits can snap during use.

Dull bits require more force to push the workpiece, possibly

causing the bit to break or the material to kick back.

The router table is designed to cut flat, straight and

squared materials. Do not cut material that is warped,

wobbly, or otherwise unstable. If the material is slightly

curved but otherwise stable, cut the material with the

concave side against the table or fence. Cutting the

material with the concave side up or away from table may

cause the warped or wobbly material to roll and kick backm

causing user to lose control.

Never start the tool when the bit is engaged in the

material. The bit cutting edge may grab the material,

causing loss of control of the workpiece.

Feed the workpiece against the rotation of the bit. The

bit rotates counterclockwise as viewed from the top of

table. Feeding the work in the wrong direction will cause the

workpiece to “climb” up on the bit, pulling the workpiece and

possibly your hands into the rotating bit.

Use push sticks, vertical and horizontally mounted

featherboards (spring sticks), and other jigs to hold

down the workpiece. Push sticks, featherboards, and

jigs eliminate the need to hold the workpiece near the

spinning bit.

4

Additional Safety Warnings for Router Tables

If an extension cord is necessary, a

cord with adequate size conductors that is capable of

carrying the current necessary for your tool must be

used. This will prevent excessive voltage drop, loss of

power or overheating. Grounded tools must use 3-wire

extension cords that have 3-prong plugs and receptacles.

NOTE: The smaller the gauge number, the heavier the cord.

RECOMMENDED SIZES OF EXTENSION CORDS

120 VOLT ALTERNATING CURRENT TOOLS

Tool’s

Ampere

Rating

Cord Size in A.W.G.

Wire Sizes in mm

2

3-6

6-8

8-10

10-12

12-16

18 16 16 14 .75 .75 1.5 2.5

18 16 14 12 .75 1.0 2.5 4.0

16 16 14 12 1.0 2.5 4.0 —

14 12 — — — — — —

25 50 100 150 15 30 60 120

Cord Length in Feet Cord Length in Meters

Important Information About Extension Cords

Improper Fence Location and Workpiece Feed

The fence and/or workpiece are

improperly located anytime it would result in:

• The front of the bit being exposed during the actual

cutting (Fig. A).

• “Climb-cutting” – The bit must not enter the workpiece in

the same direction as the feed direction, which is likely

to cause the workpiece to “climb” and may lead to loss

of control during operation (Fig. B).

“Fence Traps”: One type of improper fence location

warrants special attention. “Fence traps” happen when

the fence is positioned so far back that the front side

(power switch side) of the workpiece would be behind

the router bit.

Fence traps are dangerous for two

reasons:

• Exposure of the bit on the front side (power switch side)

of the workpiece.

• Likelihood of climb cut, which can cause loss of control.

Fig. A shows a fence trap.

Do not feed the workpiece from left to right: (Fig. B)

• It would cause climb-cutting.

• It would be difficult to keep the workpiece against the

fence faces because the bit rotation would push the

workpiece away from the fence.

FIG. A

FIG. B

WORKPIECE

EXPOSED BIT

WORKPIECE

CLIMB-CUTTING

DIRECTION

OF FEED

CORRECT

DIRECTION

OF FEED

INCORRECT

DIRECTION

Piloted bits along with the starter pin are used when

routing internal and external contours on the workpiece.

Use the auxiliary bit guard when shaping material with

the starter pin and piloted bits. The starter pin and

bearing of the piloted bit assist in maintaining control

of the workpiece.

Do not use the table as a workbench or work surface.

Using it for purposes other than routing may cause damage

and make it unsafe to use in routing.

Never stand on the table or use as a ladder or

scaffolding. Table could tip or the cutting tool could

be accidentally contacted.

Use only Bosch replacement parts. Any others may

create a hazard.

I

5

IMPORTANT: Some of the following symbols may be used on your tool. Please study them and learn their

meaning. Proper interpretation of these symbols will allow you to operate the tool better and safer.

Symbol Name Designation/Explanation

V Volts Voltage (potential)

A Amperes Current

Hz Hertz Frequency (cycles per second)

W Watt Power

kg Kilograms Weight

min Minutes Time

s Seconds Time

Ø Diameter Size of drill bits, grinding wheels, etc.

n0 No load speed Rotational speed, at no load

.../min Revolutions or reciprocation Revolutions, strokes, surface speed, orbits

per minute etc. per minute

0 Off position Zero speed, zero torque...

1, 2, 3, ... Selector settings Speed, torque, or position settings

I, II, III, Higher number means greater speed

Infinitely variable selector Speed is increasing from 0 setting

with off

Arrow Action in the direction of arrow

Alternating current Type or a characteristic of current

Direct current Type or a characteristic of current

Alternating or direct current Type or a characteristic of current

Class II construction Designates double-insulated construction tools

Earthing terminal Grounding terminal

Warning symbol Alerts user to warning messages

Ni-Cad RBRC seal Designates Ni-Cad battery recycling program

Symbols

0

This symbol designates

that this tool is listed by

Underwriters Laboratories.

This symbol designates

that this tool is listed

by the Canadian

Standards Association.

This symbol designates that

this tool is listed to Canadian

Standards by Underwriters

Laboratories.

This symbol designates that

this tool complies to NOM

Mexican Standards.

This symbol designates that this

tool is listed by Underwriters

Laboratories and listed to

Canadian Standards by

Underwriters Laboratories.

This symbol designates that

components of this tool are

listed by Underwriters

Laboratories and listed to

Canadian Standards by

Underwriters Laboratories.

6

Parts List

Refer to Parts List below and on pages 7–9.

• If ANY of the parts are missing,

DO NOT attempt to assemble, install, or use your

router table until the missing parts have been found

or replaced and your router table has been properly

and correctly assembled per this manual.

• For missing parts or technical assistance,

call 1-877-BOSCH99 (877-267-2499).

• In order to simplify handling and to minimize any

damage that may occur during shipping, your

router table comes unassembled.

• Separate all parts from the packaging materials

and check each part against the illustrations and

the parts lists to make sure that all parts have

been included. Do this before discarding any of

the packaging material.

Key No. Description Quantity

ROUTER TABLE ASSEMBLY

1 Router Tabletop 1

2 Aluminum Miter Channel 1

3 Router Mounting Plate 1

4 Left Side Panel 1

5 Right Side Panel 1

6 Back Panel 1

7 Router Table Base 1

8 Router Table Door 1

9 Tabletop Insert w/ 1″ dia. hole 1

10 Tabletop Insert w/ 2″ dia. hole 1

11 Tabletop Insert w/ 2

3

⁄4″ dia. hole 1

12 Door Hinge (may be preinstalled on door) 2

13A Magnetic Door Catch 1

13B Door Catch Plate 1

14 Switch Assembly With Lockout Key 1

15 Switch Mounting Bracket 1

Fence Assembly

16 Aluminum Fence 1

17 Fence Facing 2

18 Vacuum Port 1

19 Large Clamping Knob (in hardware bag) 6

20 Overhead Guard 1

21 Spacer (in hardware bag) 6

22 Small Clamping Knob (in hardware bag) 6

23 1/16″ Jointing Shim 2

24 Featherboard 2

25A Lower Featherboard Slide Plate 1

25B Upper Featherboard Slide Plate 1

Starter Pin Assembly

26 Starter Pin 1

27 Starter Pin Guard 1

28 #10-32 x 3/8″ Truss-Head Screw 1

Items Not Illustrated

Operating/Safety Instructions 1

7

Parts List

Featherboard

Tabletop Inserts

1

4

11

10

9

6

24

21

22

2

3

5

7

8

14

Door

Hardware

15

12

13A

Switch Assembly

13B

Fence Assembly

18

19

17

23

16

20

22

21

25A

26

28

Starter Pin Assembly

27

25B

8

Parts List

Key No. Description Quantity

FASTENERS (FOR TABLE AND FENCE ASSEMBLY)

29 #10-32 KEPS Nut 9

30 Small Washer 5

31 Large Washer 6

32 #10-32 Leveling Insert (may be preinstalled in tabletop) 4

33 #10-32 x 1/2″ Pan-Head Phillips Machine Screw 6

34 #10-32 x 1

1

⁄2″ Pan-Head Phillips Machine Screw 2

35 5/8″ lg. Flat-Head Phillips Wood Screws † 11

36 #10-32 x 7/8″ Countersunk Phillips Machine Screw 3

37 #10-32 x 5/8″ Countersunk Phillips Machine Screw 2

38 Allen-Head Connector Screw 13

39 1/4-20 x 1″ Carriage Bolt 4

40 1/4-20 x 1

1

⁄2″ Carriage Bolt 6

41 1/4-20 x 1

3

⁄4″ Carriage Bolt 2

42 6mm Hex Key (Allen Wrench) 1

43 4mm Hex Key (Allen Wrench) 1

FASTENERS (FOR MOUNTING ROUTERS)

31 Large Washer 4

44 #10-32 x 3/4″ Pan-Head Phillips Machine Screw 3

45 1/4-20 x 1

1

⁄2″ Pan-Head Phillips Machine Screw 4

46 #10-24 x 3/4″ Pan-Head Phillips Machine Screw 3

47 #8-32 x 3/4″ Pan-Head Phillips Machine Screw 3

48 1/4-20 KEPS Nut 4

NOTE: The hardware bag contains fasteners for several models. Some fasteners may not be used in the

assembly of this model. Refer to the parts list above for the correct sizes and quantities used with this table.

(32) #10-32 Leveling Insert

(30) Small Washer

(29) #10-32

KEPS Nut

(31) Large Washer

(36) #10-32 x 7/8″

Countersunk Phillips

Machine Screw

(35) 5/8″ Flat-Head

Phillips Wood Screw

(34) #10-32 x 1

1

⁄

2

″

Pan-Head Phillips

Machine Screw

(33) #10-32 x 1/2″

Pan-Head Phillips

Machine Screw

† 4 may be preinstalled on the hinges

9

Parts List

(39) 1/4-20 x 1″

Carriage Bolt

(40) 1/4-20 x 1

1

⁄2″ Carriage Bolt

(38) Allen-Head Connector Screw

(42) 6mm Hex Key

(43) 4mm Hex Key

(37) #10-32 x 5/8″

Countersunk Phillips

Machine Screw

(41) 1/4-20 x 1

3

⁄4″ Carriage Bolt

(45) 1/4-20 x 1

1

⁄

2

″ Pan-Head

Phillips Machine Screw

(46) #10-24 x 3/4″ Pan-Head

Phillips Machine Screw

(44) #10-32 x 3/4″ Pan-Head

Phillips Machine Screw

(48) 1/4-20

KEPS Nut

(47) #8-32 x 3/4″ Pan-Head

Phillips Machine Screw

10

Router Table Assembly

ATTACHING THE BASE (Fig. 2)

1.Turn the sides/back assembly upside down, and

position the base (7), with countersunk holes on

the base facing out, on the sides/back.

2.Align the holes in the base with the holes in the sides

and back, and attach using five Allen-head connector

screws (38) (Fig. 2).

3.Tighten all fasteners securely with the 4mm hex key

(43). The screw head should be in the counterbore,

below the panel surface. DO NOT OVERTIGHTEN!

FIG. 2

ASSEMBLING THE ROUTER TABLE

TOOLS REQUIRED

• #1 and #2 Phillips screwdrivers (not included)

• 3/8″ wrench or nutdriver (not included)

• 4mm hex key (included)

HINT: Applying bar soap or bees wax to the screw

threads (35 and 38) will make them easier to install

into the panels.

ASSEMBLE SIDES TO BACK (Fig. 1)

NOTE: The mounting holes for the left and right panels

are spaced so that the panel will only fit on the correct

end of the back. Before attaching the panels, make

sure that the predrilled holes for the hinges and door

catch are on the INSIDE surface of the panel.

1.Holding the back panel (6) upright, with the cord

cutout on the left (see Fig. 1), attach the left side

panel (4) to the back panel using two Allen-head

connector screws (38).

2.Attach the right side panel (5) to the back panel using

two Allen-head connector screws (38).

3.Tighten all fasteners securely with the 4mm hex key

(43). The screw head will stand slightly above the

panel surface. DO NOT OVERTIGHTEN!

6

38

4

5

FIG. 1

38

7

Router Table Assembly

ATTACHING THE SWITCH TO THE

TABLETOP (Fig. 3)

Assembly Hint: It may be easier to attach the switch

bracket if you stand the tabletop on its back edge for

this step.

1.Align the two holes in the switch mounting bracket

(15) with the two through-holes in the router tabletop.

From the top side of the table, insert two #10-32 x

1

⁄2″ pan-head machine screws (34) through the

tabletop and bracket and secure the bracket in place

with two small washers (30) and two #10-32 KEPS

nuts (29) (Fig. 3).

2.Insert two #10-32 KEPS nuts (29) into the

hex-shaped recesses in the back of the switch

assembly (14) with the toothed washer facing away

from the recess. Secure the switch to the switch

mounting bracket with two #10-32 x 1/2″ pan-head

machine screws (33) while holding the KEPS nuts in

place in the recess with your finger.

11

34

15

14

29

33

FIG. 3

DETAIL 3

ATTACH THE TABLETOP (Fig. 4)

NOTE: The tabletop may be shipped with the miter

channel in place. To access the tabletop mounting

holes, remove the channel for this step.

1.With the base assembly upright, position the

tabletop (1) on the base assembly, making sure

the switch is in the front, as shown in Fig. 4.

2.Secure the tabletop to the base with four Allen-head

connector screws (38).

3.Tighten all fasteners securely with the 4mm hex key.

The screw head should be in the counterbore, below

the panel surface. DO NOT OVERTIGHTEN!

1

38

FIG. 4

ASSEMBLE THE ALUMINUM MITER

CHANNEL TO THE TABLETOP (Fig. 5)

Assembly Hint: It may be easier to install the miter

channel if you lay the table on its back for this step.

1.Center the miter channel (2) in the slot on the

tabletop; then press the miter channel into the slot.

2.From the top side of the tabletop (1), insert three

#10-32 x 7/8

″

countersunk Phillips machine screws

(36) through the holes in the miter channel (2) and

the tabletop (Fig. 5).

3.Secure with a small washer (30) and a #10-32 KEPS

nut (29) on each screw.

36

30

29

2

FIG. 5

14

30

12

Router Table Assembly

ATTACH THE DOOR (Figs. 6 and 7)

HINT: Applying bar soap or bees wax to the screw

threads will make them easier to install into the panels.

1.With the bumps on the catch plate against the door

surface, attach the metal catch plate (13B) to the

inside of the narrow end of the door with a 5/8″ lg.

flat-head Phillips wood screw (35). The edge of the

catch plate should be even with the edge of the door

(Fig. 6).

2.Attach the door hinges (12) to the left side panel with

two 5/8″ lg. flat-head Phillips wood screws (35) on

each hinge (Fig. 7).

3.Attach the magnetic catch (13A) to the inside of the

right side panel using two 5/8″ lg. flat-head Phillips

wood screws (35) (Fig. 7).

4.Slowly open and close the door, making sure that it

moves freely and does not rub on the base or top,

does not come in contact with the switch assembly,

and that it latches correctly.

• If the door rubs, make sure the side panels and

switch are assembled correctly.

• If the magnetic catch does not contact the

catch plate, loosen the screws on the magnetic

catch and reposition it using the slotted holes

in the catch.

Back Side of Door

13B

35

13A

35

12

FIG. 6

FIG.7

13

Router Table Assembly

ASSEMBLING THE FENCE

ASSEMBLING THE FENCE (Figs. 8 and 9)

1.Insert the pins molded into the top of the vacuum

port (18) into the holes on the rear of the aluminum

fence (16), as shown in Fig. 8.

2.From the underside of the fence, insert two

#10-32 x 5/8″ countersunk machine screws (37)

up through the holes in the bottom of the fence and

vacuum port. Secure in place with two #10-32 KEPS

nuts (29) (Fig. 8).

3.Place the fence right-side-up on a flat surface and

align the counterbored holes in the fence facings (17)

with the slotted holes in the fence. The counterbored

side of the facings should face OUT (Fig. 9).

4. Attach both fence facings (17) to the front of the fence,

using two 1/4-20 x 1″ carriage bolts (39) and two large

clamping knobs (19) for each fence facing (Fig. 9).

5. From the front of the overhead guard (20), insert two

1/4-20 x 1

1

⁄2″ carriage bolts (40) through the holes in the

guard. Slide a spacer (21) on each bolt so that the tabs

on the spacers fit into the slots on the guard.

6. From the front of the fence, insert the carriage bolts

through the holes in the top center of the fence. The

tabs on the spacers will fit into the top channel on the

fence. Secure in place with a small clamping knob (22)

on each bolt (Fig. 9).

NOTE: To simplify installation of the router adapter plate

and router, do not install the fence onto the router table

at this time.

37

29

18

16

19

21

17

NOTE: Two plastic jointing shims (23) are included to

provide the proper fence offset when jointing. For

more about jointing operations and shim placement,

see page 27.

FIG. 8

FIG. 9

22

39

40

20

14

Router Table Assembly

DETERMINE THE MOUNTING METHOD TO

BE USED (see chart on page 15)

If your router model is listed in the chart on page

15, proceed to step 1 below. If it is NOT listed, you

must purchase a BOSCH RA1186 Router Adapter

Plate, available separately.

If your router model IS listed:

1.Determine the hole pattern that matches the

mounting hole pattern for your router.

2.Determine which fasteners you will need to attach the

router to the router adapter plate.

3.Determine which mount type (1 or 2) is used for your

router model.

SELECTING THE ROUTER HOLE PATTERN

TOP FRONT OF PLATE

FIG. 10

MOUNTING PLATE GUIDE FOR COMPATIBLE ROUTERS (Fig. 10)

A

C

D

B

1/4-28 THREADED

HOLE FOR

STARTER PIN

A

B

D

C

10-32 THREADED

HOLE FOR STARTER

PIN GUARD

OVER-TABLE

ADJUSTMENT HOLE

MOUNT TYPE 1

MOUNT TYPE 2

MOUNTING PLATE

ROUTER BASE

MOUNTING PLATE

ROUTER BASE

BEFORE USING THE ROUTER TABLE, REFER TO THE ROUTER

OWNER’S MANUAL FOR OPERATION INFORMATION.

15

Router Table Assembly

Router Router Hole Fasteners Mount

Brand Model Pattern Required Type

Bosch 1613 series A 1/4-20 x 1

1

⁄2″ Phillips machine screws (45), 2

large washers (31), and 1/4-20 nuts (48)

Bosch 1617 series B 10-24 x 3/4″ Phillips machine screws (46) 1

(fixed base

models only)

Bosch 1619EVS C 1/4-20 x 1

1

⁄2″ Phillips machine screws (45), 2

large washers (31), and 1/4-20 nuts (48)

DeWalt DW616, DW618 B #8-32 x 3/4″ Phillips machine screws (47) 1

(fixed base only)

Hitachi M12VC B #10-32 x 3/4″ Phillips machine screws (44) 1

Makita RF1100, RF1101 B #10-24 x 3/4″ Phillips machine screws (46) 1

Milwaukee 5615, 5616 B #10-24 x 3/4″ Phillips machine screws (46) 1

Porter Cable 690 series, B #10-24 x 3/4″ Phillips machine screws (46) 1

7529 plunge router,

and 892–895 series

(fixed base only)

ATTACH ROUTER TO MOUNTING PLATE

(Figs. 11 and 12)

1.Remove the plastic subbase from your router

(Fig. 11).

2.If your router has its own dust extraction hood that

mounts to the top of the metal router base and you

want to use it under the router table, this is a

convenient time to install it.

3.Using Chart 1, determine the hardware and mount

type for your router.

• For most router models, the screws are driven into

threaded holes in the router’s base (mount type 1).

• For some router models, the screws go all the way

through the base and are fastened with washers

and nuts (mount type 2).

The top and front of the mounting plate is determined

by the location of the guide pin holes. These holes

are to the right of the bit opening.

4.Refer to the mounting plate guide (Fig. 10) on page

14 and align the appropriate mounting plate holes for

your router to the router base holes. Make sure that

the depth adjustment controls on the router face the

front of the mounting plate.

5.Mount your router to the mounting plate (Fig. 12).

FIG. 11

REMOVE

SUBBASE

FIG. 12

CHART 1

16

Router Table Assembly

ATTACH THE ROUTER MOUNTING PLATE

(Fig. 13)

1.If the fence is already installed on the table, remove it

before proceeding.

2.Place the router mounting plate (3) in the opening so

the numbers on the scales are right side up, as seen

from the front of the table. Using a straight edge,

check to be certain that the surface of the router

mounting plate is flush with the tabletop surface.

NOTE: Failure to make sure the router mounting

plate is flush with the tabletop surface can result in

poor routing performance. Slide a square cut board

from right to left across the router mounting plate to

be sure that it moves smoothly.

3. To adjust the plate, insert the 6mm hex key through

the outermost corner holes in the mounting plate

and turn the leveling inserts clockwise to lower the

mounting plate or counterclockwise to raise the

mounting plate.

3

33

FIG. 13

OVER-TABLE HEIGHT ADJUSTMENT

The router adapter plate features an access hole to

allow use with the over-table height adjustment feature

on the Bosch 1617 series routers. Refer to your router

manual for additional information on using this feature.

For the Porter Cable 892 and 895 and the Milwaukee

5615 and 5616 model routers, it is necessary to drill

an access hole to accommodate the over-table height

adjustment:

1.Remove the subbase from the router and align

the mounting holes in the subbase with the

corresponding mounting holes in the adapter plate.

Be sure to orient the subbase so that the router

switch will be toward the front of the table.

4.Secure the router mounting plate (3) to the table

with four #10-32 x 1/2″ pan-head machine screws

(33) (Fig. 13) through the outermost corner holes in

the plate. Tighten the screws snugly, but do not

overtighten.

2.Using a pencil or centerpunch, mark the location of

the over-table height adjustment hole on the router

adapter plate.

3.Remove the subbase from the adapter plate and

carefully drill the over-table height adjustment hole.

4.Make sure that the hole will accommodate the height

adjustment tool for your router. Remove any burrs or

rough edges with sandpaper.

TO REMOVE THE ROUTER AND/OR

ROUTER MOUNTING PLATE

To remove the router from the mounting plate, you

must first remove the router mounting plate from the

router table.

THE FENCE MUST BE REMOVED FROM THE

ROUTER TABLE WHEN REMOVING OR

REINSTALLING THE ROUTER MOUNTING PLATE.

Make sure that the router is NOT

plugged into a power outlet when installing into the

table, removing from table, making adjustments or

changing accessories. Router could accidentally start.

1.Loosen the four #10-32 x 1/2″ pan-head Phillips

machine screws (33) holding the router mounting

plate to the tabletop.

2.Lift the router mounting plate and router upwards

from the tabletop.

3.Remove the countersunk machine screws securing

the router to the mounting plate.

4.When reinstalling the router mounting plate, be sure

that the plate is level with the tabletop. If needed,

readjust as described above.

17

THE ROUTER TABLE MUST

BE SECURED TO A STABLE WORK SURFACE

WHENEVER IT IS IN USE. FAILURE TO DO

SO COULD CAUSE IT TO TIP OR SHIFT

UNEXPECTEDLY.

SECURING THE ROUTER TABLE TO A

WORK SURFACE (Fig. 15)

Preferred method:

The base of the router table has four mounting holes.

These holes can be used to attach it to a workbench

or work surface with four 1/4″ wood screws and

washers or bolts, washers, and nuts (not provided).

1/4″ WOOD SCREWS OR BOLTS

C-CLAMPS

FIG. 15

OR

Router Table Assembly

ATTACHING THE FENCE TO THE TABLE

(Fig. 14)

1.From underneath, slide two 1/4-20 x 1

3

⁄4″ carriage

bolts (41) up through the holes in the bottom of the

fence. Slide a large washer (31) onto each bolt and

loosely attach a large clamping knob (19) onto

each bolt.

2.Insert the carriage bolt heads through the holes of the

J-slots on the tabletop, making sure the bolt head is

below the inside surface of the tabletop and can slide

freely into the J-slot.

3.Slide the fence assembly left and into the J-slot and

make sure that it slides smoothly from front to back.

NOTE: Use the scale on the tabletop as a guide

when aligning the fence for routing operations. Once

the fence is positioned and aligned correctly, tighten

the clamping knobs SECURELY.

19

FIG. 14

31

HINT: Position the router table in the desired location

and mark the hole locations using the holes in the table

base. Then drill suitable pilot (for wood screws) or

through-holes (for bolts).

Alternative method:

The base can be secured to a workbench or work

surface with C-clamps.

41

18

Router Table Assembly

ALWAYS MAKE SURE THAT

THE ROUTER IS TURNED OFF AND THE POWER

CORD IS UNPLUGGED BEFORE MAKING

ANY ADJUSTMENTS.

TABLETOP INSERTS (Fig. 16)

This router table includes three tabletop inserts with the

following hole sizes:

• 1″ in diameter (9), for use with bits with diameters up

to 7/8″

• 2″ in diameter (10), for use with bits with diameters up

to 1

7

⁄8″

• 2

3

⁄4″ in diameter (11), for use with bits with diameters

up to 2

5

⁄8″

No insert is used for bits with diameters over 2

5

⁄8″ and

up to 3

1

⁄2″.

Do NOT use the router table with

bits over 3

1

⁄2″ in diameter!

TO INSTALL TABLETOP INSERTS (Fig. 16):

1.Select the tabletop insert that best accommodates

the router bit to be used.

2.Press the insert into the large hole in the router

mounting plate (Fig. 16). If the fence is in the way,

loosen the clamping knobs on the fence and slide the

fence back out of the way.

3.Press down evenly over the tabs until the insert locks

into place.

4.To remove, pull up gently until the tabs disengage.

When not in use, store tabletop inserts in a

resealable plastic bag in the router table cabinet.

DO NOT attempt to remove

tabletop inserts from the tabletop unless the

router is unplugged.

1″ HOLE (9)

2″ HOLE (10)

2

3

⁄4″ HOLE (11)

3

5

⁄8″ HOLE

IN ROUTER

MOUNTING

PLATE

FIG. 16

19

Router Table Operation

SWITCH INSTRUCTIONS

ELECTRICAL REQUIREMENTS

A 14-gauge (or heavier) three-wire extension cord with

a three-hole grounding receptacle and three-hole

grounding plug is to be used for connecting the

switch to an electrical outlet.

DAMAGED OR WORN EXTENSION CORDS

ARE NOT TO BE USED AND ARE TO BE

REPLACED IMMEDIATELY.

The electrical cord at the back of the switch will accept

three-hole extension cords.

The electrical receptacles at the back of the switch will

accept either three-prong or two-prong plugs from a

router or accessory.

In the event of a malfunction or breakdown, grounding

provides the path of least resistance for electrical

current in order to reduce the risk of electrical shock.

This switch box is equipped with an electrical cord

that has an equipment-grounding connector and a

grounding plug.

The extension cord must be plugged into a matching

outlet that has been installed by a licensed

electrician and grounded in accordance with

all local codes and ordinances.

DO NOT modify the plug from the switch if it does not

plug into the extension cord. Obtain an extension cord

with the proper outlet.

Improper connection of the equipment-grounding

conductor can result in risk of an electrical shock.

The conductor with insulation that has a green outer

surface, with or without yellow stripes, is the equipment-

grounding conductor.

DO NOT CONNECT THE EQUIPMENT-GROUNDING

CONDUCTOR TO A LIVE TERMINAL.

Check with a licensed electrician if the grounding

instructions are not completely understood, or if there

is doubt as to whether the electrical outlet or extension

cord is properly grounded.

DO NOT PERMIT FINGERS

TO TOUCH TERMINALS OF THE PLUG WHEN

PLUGGING IT INTO OR REMOVING IT FROM

THE OUTLET.

IF NOT PROPERLY GROUNDED,

A POWER TOOL CAN PRESENT POTENTIAL

HAZARDS OF ELECTRICAL SHOCK, WHICH CAN

POSSIBLY RESULT IN SERIOUS BODILY INJURY

OR DEATH, particularly when used in a damp

location, in proximity to plumbing, or out-of-doors.

If an electrical shock occurs, there is always the

potential of a secondary hazard, such as your

hands contacting the router bit, or falling down

or against an object.

USE THE SWITCH BOX ONLY

WHEN PROPERLY ASSEMBLED TO THE ROUTER

TABLE. USE ONLY WITH A ROUTER THAT HAS

ALSO BEEN PROPERLY INSTALLED ON A

PROPERLY ASSEMBLED ROUTER TABLE.

THE SWITCH HAS A RATING OF

15 AMPS. DO NOT EXCEED A TOTAL COMBINED

RATING OF 15 AMPS WHEN CONNECTING THE

ROUTER AND ANY ACCESSORIES SUCH AS A

LIGHT OR WET/DRY VACUUM.

20

GENERAL INFORMATION

The power switch is designed for use with most

BOSCH Router Tables. It provides the convenience

of an ON (RESET)-OFF switch at the front of the

table, thus eliminating the need to reach underneath

the table to turn the router ON and OFF.

The power switch also provides an optional

simultaneous ON-OFF control of an additional

accessory, such as a light or wet/dry vac.

The switch has an internal, resettable circuit

breaker to provide overload protection.

Cord Routing

Route the switch cord and any accessory power

cords through the notch in the vacuum port on the

back of the router table cabinet.

VAC PORT ON

BACK OF TABLE

SWITCH AND

ACCESSORY

CORDS

CONNECTING THE ROUTER POWER CORD

TO THE SWITCH

• MAKE SURE THAT THE SWITCH POWER CORD IS

NOT PLUGGED INTO ANY ELECTRICAL OUTLET

AT THIS TIME. IF IT IS, UNPLUG IT.

• MAKE SURE THAT ROUTER SWITCH IS IN THE

OFF POSITION.

1.Plug the router power cord into one of the electrical

outlets on the back of the switch case.

2.Form the excess power cord into a coil.

3.Wrap two pieces of friction tape or cable ties around

the coiled cord at opposite sides of the coil.

4.Allow some slack so that the cord does not become

stretched when it is plugged into the switch box

outlets.

5.If desired, at this time plug the power cord from an

accessory, such as a wet/dry vac or light, into the

other outlet on the back of the switch case.

MAKE SURE THAT POWER

CORDS FROM THE ROUTER, ACCESSORIES, THE

SWITCH CASE, AND THE EXTENSION CORD DO

NOT AND CANNOT COME IN CONTACT WITH THE

ROUTER OR ANY MOVING PARTS OF THE

ROUTER.

• This switch has a 15 amp rating and is intended

only for turning the router and connected acces-

sories such as a wet/dry vacuum “ON” and “OFF”.

Router Table Operation

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